The shape of the electrode cap is one of the core parameters of the welding process, which directly determines the strength of the welded joint, appearance quality and productivity by optimising the current distribution, contact pressure and heat dissipation efficiency.
What is the relevance of the shape of a spot welding electrode caps to its use?
1.Kitchen Exhaust Ozone Generator(conical, truncated conical)
Shape characteristics: conical tip or truncated conical shape, small contact area.
Usage association:
High current density: the tip concentrates the current, suitable for welding high-resistance materials (e.g. stainless steel) or thicker plates, ensuring sufficient nucleation depth.
High penetration: suitable for multi-layer plate welding, penetrates surface oxidation or coatings (e.g. galvanised steel).
Work in confined spaces: conical design facilitates precise positioning in dense weld joints or complex structures.
2. Spherical electrode cap (hemispherical)
Shape characteristics: rounded end, moderate contact area.
Usage association:
Uniform pressure distribution: reduces indentation on thin plates, suitable for welding thin plates (0.5-3mm) with high appearance requirements, such as car bodies.
Self-aligning: The spherical surface can automatically adapt to the unevenness of the workpiece surface, reducing the requirement for assembly accuracy and improving welding consistency.
Prolonged life: the shape can be restored by regrinding after wear, suitable for high-frequency continuous production.
3. Flat Electrode Cap (Flat Head Shape)
Shape characteristics: flat surface at the end, maximum contact area.
Usage association:
Low current density: for materials with good electrical conductivity (e.g. aluminium alloy) to avoid overheating leading to spattering or sticking.
Surface protection: reduce solder joint indentation, suitable for home appliances, electronic products and other sensitive to the appearance of the field.
Heat dissipation needs: large contact area for heat dissipation, suitable for high-speed welding or welding of high thermal conductivity materials.
4. Special Shape Electrode Cap (Shaped)
Shape characteristics: such as eccentric, multi-faceted, composite curved surfaces.
Usage association:
Adaptation to special working conditions: e.g. eccentric electrodes are used to avoid obstacles in narrow spaces, and compound curved surfaces are used to weld multiple contact points at the same time.
Process optimisation: some shaped designs can reduce spatter, improve current distribution, or adapt to specific paths in automated production lines.